GPA FACILITY SAFETY-1998 Gas Processing Facility Safety Inspection Checklist.pdf

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1、GAS PROCESSING FACILITY SAFETY ! NSPECTION CHECKLIST :- Gas Processors Association 6526 E. 60th Street Tulsa, OK 74145 Phone: (918) 493-3872 Fax: (918) 493-3875 Home Page: http:/ E-mail: pp GAS PROCESSING FACILITY SAFETY INSPECTION CHECKLIST DISCLAIMER t The Safety Inspection Checklist was develope

2、d through the GPA Safety Committee. The information contained in the checklist is to be taken as suggestions based on the experience of Committee members and member companies as of the date of publication. The checklist items are not regulations, requirements or minimum standards; they must be edite

3、d to fit the situation of the individual/company. The information contained in this publication should be reviewed by appropriate parties before implementing adopted practices. Neither GPA, nor any member of the Safety committee, make any warranty, guarantee or representation, express or implied, wi

4、th respect to the accuracy, completeness, or usefulness of the information contained in this publication. The checklist is not intended to be a replacement for detailed engineering or operations analysis but to be a tool to identify potential areas of concerns. Copyright1998 by Gas Processors Associ

5、ation All rights reserved. No parts of this publication may be reproduced without the written consent of the Gas Processors Association. INTRODUCTION ii Date Revised : October 20, 1998 GAS PROCESSING FACILITY SAFETY INSPECTION CHECKLIST FOREWORD In 1970, GPA Technical Section A undertook the task of

6、 developing a checklist on plant design. In 1978, the Board of Directors requested the Technical Committee to prepare a similar work on energy conservation. It was completed in 1981. These two publications cover their title subjects well but make only casual reference to safety. To fill this void, t

7、he GPA Safety Committee agreed during their October, 1982 meeting to develop a safety checklist. The initial task force was chaired by Richard Bausell, Cities Service Oil & Gas Corp., with Joel Tietjens, Mitchell Energy, and William E. Childers as members. Through the next four years, numerous Safet

8、y Committee members worked on parts of the check list. (1) The last draft was completed in 1986. The final work, “Gas Processing Facility Safety Inspection Checklist“, was published in early 1987. The industry extends its sincere thanks to the initial task force, committee members and to those unnam

9、ed and unheralded individuals who contributed their time and expertise in the preparation of this publication. In addition, a special thanks to Leona Steinbarge of Mitchell Energy and Development Corporation for providing many hours to organize and prepare this document. As part of the 1996 GPA Safe

10、ty Committee “Vision 2000“ effort led by Steve Godby and Mike Burgess, it was decided by the Committee that the GPA “Gas Processing Facility Safety Inspection Checklist“ should be updated to reflect recent legislative considerations such as OSHA 1910.119, Process Safety Management. A team composed o

11、f Jeff Smith, Mobil, John Farrah, Marathon, Dan Kalisek, Marathon, Beth Hutton, Texaco, John Williams, Mitchell 3as Services, Walt Braunlin, Terry Pelham, Marathon, Wade Ingle, KN Energy and Darrel Lester, Torch Energy, as formed to accomplish this task. Liz Powell and Brenda McGuire, Marathon, and

12、Joy Harkins, Mitchell Gas Services, provided the word processing services for the preparation of this checklist. To simplify and clarify as much as possible, the organization of the “original checklist“ was changed. It was judged that the original arrangement of the checklist was satisfactory. Howev

13、er, under each major processing category, the questions were rearranged into two major categories: (1) Regulatory Considerations and (2) Other Considerations. It is our judgement that this arrangement will provide the most usable document for the personnel who are assessing the total safety performa

14、nce and safety compliance of their plants. Please note that OSHA Process Safety Management issues reflect only activities that occurred since May 26, 1992. GPA Safety Committee Chair - Greg Lewis, Mitchell Gas Services L.P. m Additional Safety Committee Participants who developed the original list:

15、Paul J. Bettencourt Charles F. Hamilton Gene Howerton Frank B. Kern S.R. Kuiper John C. Long Mobil Oil Exploration and Producing Southeast, Inc. CSX Oil and Gas Corp. Conoco Exxon Company, U.S.A. Mobil Oil Corporation Warren Petroleum, Division of Chevron INTRODUCTION iii Date Revised : October 20,

16、1998 GAS PROCESSING FACILITY SAFETY INSPECTION CHECKLIST TABLE OF CONTENTS Section Pages Description 1. 1 - 11 General 2. 12 - 19 Process Area 3. 20 - 28 Compression Systems 4. 29 - 32 Sour Gas Treating 5. 33 - 41 Sulfur Plants 6. 42 - 46 Storage 7. 47 - 53 Tank Car/Truck Loading Area 8. 54 - 60 Boi

17、ler/Heater 9. 61 - 65 Cooling System/Air Cooled Exchangers 10. 66 - 70 Electrical Generation and Equipment 11. 71 - 74 Control Room 12. 75 - 77 Flare System 13. 78 - 82 Shop and Warehouse 14. 83 - 86 Laboratory 15. 87 - 91 Fire Protection INTRODUCTION iv Date Revised : October 20, 1998 GAS PROCESSIN

18、G FACILITY SAFETY INSPECTION CHECKLIST GENERAL PURPOSE The purpose of this section is to provide guidance to assist with your overall safety program elements. REGULATORY CONSIDERATIONS . General A. Does your facility utilize a corporate Process Safety Management (PSM) policy for guidance? B. If you

19、do not have a corporate PSM policy, do you have a site specific Process Safety Management policy? C Have efforts been made to ensure understanding of PSM policy by all employees D Does your facility have a written Hazard Communication (HAZCOM) Plan? E Does your facility have a Natural Occurring Radi

20、oactive Material (NORM) plan, if required in your state? F. Does your facility have a Safety Policy Manual? G. H. Does your facility have a Blood bome Pathogen plan? Does your facility have a personal protective equipment (PPE) plan? . I. Are the contents of the facilitys first aid kit approved by a

21、 physician? Employee Participation A. Can employees review PSM information at all times of the day? B Does your facility have a system for quick and easy reference to all Process Safety Information records? C. Is there a system available for employees to submit safety suggestions? D. Are monthly saf

22、ety meetings held? E F. Is there a Safety Committee? Does the Safety Committee meet at least once per month? YES NO N/A GENERAL 1-1 Date Revised: October 20, 1998 . . G. Are minutes kept for all Safety Committee meetings and safety meetings? H. Is your Employee Involvement policy statement posted an

23、d signed by management? I. Are employees instructed to report missing or inaccurate process safety information? J. Are employees consulted when changes in PSM policies are proposed? K. Have all employees been given the opportunity to participate in a Process Hazard Analysis (PHA)7 L. Do you have a s

24、ystem for informing employees of the results of PHAs and investigations required by the PSM program? Process Safety Information A. Are Material Safety Data Sheets (MSDS) always available? B. Are Process Flow Diagrams always available? C. Has Process Chemistry been defined and explained? D. Have safe

25、 upper and lower operating limits been developed? E. Have Consequences of Deviation been defined? F. Have Maximum Inventory Levels been defined? G. Are Materials of Construction defined? H. Are Piping and Instrumentation Drawings (P & IDs) available and current? I. Are electrical classification draw

26、ings available? J. Is relief and/or vent system design information available? K. Is building ventilation design established? L. Are the Design Codes and Standards used defined? M. Have material and energy balances been completed for processes? N. Are Safety Systems defined? Process Hazard Analysis A

27、. Are previous incidents considered during PHAs? YES NO N/A GENERAL 1-2 Date Revised: October 20, 1998 . . B. C. D. Are human factors considered during a PHA? Has facility siting been considered? Have consequences of failure of controls been defined? Operating Procedures A. Are operating procedures

28、audited and certified correct on an annual basis by the designated site supervisor? B. Are all operating procedures available to operators either electronically or in hard copy around the clock? C. Is there an ongoing effort made to develop and implement improved safe work procedures? D. Are employe

29、es encouraged to suggest changes to operating procedures? E. When equipment changes are made, are operating procedures revised before the process is restarted? F. Have abnormal operating procedures been written? G. Do the operating procedures address: 1. Standard operating parameters? 2. Consequence

30、s of deviation from the standard operating parameters? 3. Initial startup? 4. Temporary operations? 5. Emergency shutdowns? 6. Emergency operations? 7. Normal shutdown? 8. Startup after turnaround or emergency shutdown? 9. Steps to correct or avoid shutdowns? 10. Safety systems and their functions?

31、Training A. Has required training for each operating job been defined to suit the needs of the facility? YES NO N/A GENERAL 1-3 Date Revised: October 20, 1998 B. C D. Have employees been consulted concerning the optimum frequency of refresher training? Has the employee review of training frequency b

32、een documented? Has the following employee training been completed (if appropriate): . 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. New employee orientation? First Aid? Fire extinguisher/fire prevention? Hydrogen sulfide? Respiratory protection equipment? Heating c

33、onservation? Hot work procedures? Confined space entry? Emergency evacuation plan? Lockout and tagout? Use of resuscitator? Forklift? Crane? Personal protective equipment? Benzene? Asbestos? Naturally Occurring Radioactive Material (NORM)? Hazard Communication (HAZCOM) refresher? Electrical safe wor

34、k practices? Bloodborne pathogens? Resource Conservation and Recovery Act (RCRA) Waste? Employee access to medical records? Others not noted here? YES NO N/A GENERAL 1-4 Date Revised: October 20, 1998 . . . Contractors A. Has an “Approved Contractor List“ been developed for use by the facility? B. A

35、re minimum contractor safety performance standards defined for each type of work performed at the facility? C. Are specific process hazards included in the contractor orientation? D. Is a site specific orientation program available? E. Is special training required for individuals performing speciali

36、zed work such as vessel entry? F. Is contractor safety performance reviewed and documented? G. Is there a procedure for controlling access/egress to plant? H. Is there a procedure for verifying contractor qualifications? I. Does the facility maintain a log of contractor accidents? Pre-startup Safety

37、 Review A. Are operators included in each pre-startup safety review7 B. Are operating procedures reviewed by the operators before startup? C. Are maintenance procedures reviewed by the maintenance personnel before startup? Mechanical Integrity A. Are all preventive maintenance (PM) frequencies and j

38、ob content defined in the inspection procedures? B. Is there a system to define needed work and track work done? (ie, work orders) C. Is there a current safe practices and procedures manual? D. Is there a procedure to inspect and approve all materials received for suitability for their application?

39、E. Is there a maintenance training program? F. Is input solicited from maintenance employees concerning equipment inspection and testing procedures? G. Are mechanical integrity records available at the facility? YES NO N/A GENERAL 1-5 Date Revised: October 20, 1998 10. 11. 12. H. Are safety relief v

40、alves included in the PM program? I. Are there authorized employees for each task? J. Are emergency shutdown (ESD) valves included in the PM program? Hot Work Permit A. Is there a hot work permit system? B. Are issuers of hot work permits trained to perform their duties? C. Are records kept of all h

41、ot work permits completed for a designated time period? D. Are suitable atmosphere monitoring devices (HaS , LEL, 02, etc., as applicable) available? E. Are employees aware that they are to notify supervision if they see hot work being done without a permit? F. Are employees aware that they are to n

42、otify supervision if they observe work being done that is not within the restrictions of the hot work permit? Management of Change (MOC) A. Is there an MOC procedure in place? B. Is an MOC completed for replacement not in-kind? C. Is training on MOes documented before a new process is put into servi

43、ce? Incident Investigation A. Are employees trained as to what a PSM incident is? B. Is there a defined policy for investigating an incident? 1. Does the policy require that investigations commence within 48 hours? 2. Does the policy require that team membership include: a. A person knowledgeable in

44、 the process? b. A person trained in incident investigation? c. Affected employees? YES NO N/A GENERAL 1-6 Date Revised: October 20, 1998 13. 14. 15. d. Affected contractors? (if appropriate) C. Is there a discussion of recommendations with affected employees? D. Is there a follow-up and are employe

45、es included in the follow-up? Emergency Planning and Response A. Are employees involved in critiquing practice evacuation drills? B. Are employees involved in the development/updating of emergency plans? C. Does the plan address: 1. Emergency escape procedures? 2. Emergency escape routes? 3. Procedu

46、res for emergency shutdown? 4. Procedures to account for employees and/or contractors? 5. Reporting procedures for fires and other emergencies? 6. Names and numbers for persons to contact for information regarding the plan? D. Is there an audible alarm provided for emergencies? E. Is the alarm maint

47、ained and tested routinely? F. Are employees trained in emergency procedures commensurate with their duties? Compliance Audits A Have PSM audits been completed as required? B. Are they signed by a responsible person? C. Are the past two compliance audits available? OSHA Recordkeeping A. Are OSHA rec

48、ords of injury/illness (200 logs) kept current? (injuries/illness recorded within 6 days) B. Are the past five years of OSHA records of injury/illness kept on file? C. Are the OSHA records of injury/illness posted each year (Feb. 1 - March 1) for the prior year? YES NO N/A GENERAL 1-7 Date Revised:

49、October 20, 1998 J. K. L. POSTINGS RECORDS 1. Are the following records on file and up-to-date: A. Material Safety Data Sheets? B. Fire extinguisher inspections? (Monthly and Annual) C. Alarm and shutdown testing? D. Relief valve testing? E. Safety meeting minutes and attendance? F. Safety committee meeting minutes? G. Gas detection equipment calibration and testing? H. Domestic fuel gas odorization records and reports? I. Hydrostatic testing and radiography of piping, pressure vessels and other equipment? Fire water pump operational log? Crane